CN117412855A - Wear-resistant decorative surface coverings and process for making same - Google Patents

Wear-resistant decorative surface coverings and process for making same Download PDF

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Publication number
CN117412855A
CN117412855A CN202280038230.XA CN202280038230A CN117412855A CN 117412855 A CN117412855 A CN 117412855A CN 202280038230 A CN202280038230 A CN 202280038230A CN 117412855 A CN117412855 A CN 117412855A
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CN
China
Prior art keywords
layer
decorative surface
surface covering
thermoplastic composition
meth
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Pending
Application number
CN202280038230.XA
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Chinese (zh)
Inventor
尼古拉斯·博基永
阿达米克·马雷克
佩雅克·德拉甘
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Tarkett GDL SA
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Tarkett GDL SA
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Publication of CN117412855A publication Critical patent/CN117412855A/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/04—Coating on the layer surface on a particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/02—Synthetic macromolecular particles
    • B32B2264/0214—Particles made of materials belonging to B32B27/00
    • B32B2264/0228—Vinyl resin particles, e.g. polyvinyl acetate, polyvinyl alcohol polymers or ethylene-vinyl acetate copolymers
    • B32B2264/0242—Vinyl halide, e.g. PVC, PVDC, PVF or PVDF (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/404—Multi-coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/584—Scratch resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings

Abstract

A decorative surface covering (1) defining a thickness direction (N) and comprising an assembly (5), the assembly (5) having, in the thickness direction (N): -a core layer (5A) comprising a first thermoplastic composition (12), said first thermoplastic composition (12) comprising one or more thermoplastic polymers, P1phr of one or more fillers and P2phr of one or more plasticizers, -at least one strengthening layer (5B), -a wear layer (5D) comprising at least a second thermoplastic composition (14), said second thermoplastic composition (14) comprising one or more thermoplastic polymers, P1'phr of one or more fillers and P2' phr of one or more plasticizers. P1 and P2 are greater than P1 'and P2', respectively.

Description

Wear-resistant decorative surface coverings and process for making same
The present invention relates to decorative surface coverings intended to be laid on floors, such as rolls or tiles.
The invention also relates to a method for manufacturing such a decorative surface covering.
To obtain a decorative surface covering, production of laminate panels is well known. The core layer is first produced by calendering or by using a twin belt press. Other layers (e.g., decorative and wear layers) are then subsequently laminated to the core layer to produce a board, typically cut to obtain tiles.
The twin belt press has at least a first belt on which particles of at least one thermoplastic material are dispersed. The press allows pressing and heating of the granules between the first belt and the second belt of the press in order to convert the granules into a core layer of the board.
In order to reinforce the core layer of the panel, a reinforcing layer is sometimes added to the core layer. This can be done, for example, by: a sheet of glass fibers is applied over the first particulate layer, a second particulate layer is dispersed over the sheet, and then the set is hot pressed in a twin belt press to form a core layer, which is free of a decorative layer.
Thus, in order to obtain a decorative surface covering, it is necessary to laminate a printed film on the core layer. The printed film has a decorative pattern to provide the board with a decorative appearance. To protect the printed film and provide mechanical and abrasion resistance to the upper surface of the decorative surface covering, an abrasion resistant layer may be added on top of the printed film. Furthermore, it is known to add a polyurethane layer on top of the wear layer in order to increase the surface properties of the decorative surface covering.
However, these known surface decorative coverings currently face delamination problems between the core layer and the printed film when subjected to high strength service conditions such as heavy loads or high traffic.
Thus, there is a need for a method of making a decorative surface covering that is both resistant to delamination and also retains aesthetics.
To this end, the invention proposes a decorative surface covering defining a thickness direction and comprising an assembly having, in the thickness direction:
a core layer comprising a first thermoplastic composition comprising one or more thermoplastic polymers, P1phr of one or more fillers and P2phr of one or more plasticizers,
at least one reinforcing layer, and
an abrasion resistant layer comprising at least a second thermoplastic composition comprising one or more thermoplastic polymers, P1'phr of one or more fillers, and P2' phr of one or more plasticizers,
wherein P1 and P2 are greater than P1 'and P2', respectively.
In particular embodiments, the decorative surface covering includes one or more of the following features, alone or in any technically feasible combination:
-the at least one strengthening layer comprises at least 50% glass fibres;
-without any printed film on or over the assembly;
-a coating on the wear layer, the coating comprising a radiation curable coating agent;
-the radiation curable coating agent comprises an oligomer and/or polymer selected from the group consisting of: (meth) acrylic copolymers, polyether (meth) acrylates, polyester (meth) acrylates, epoxy (meth) acrylates, urethane (meth) acrylates, amino (meth) acrylates, melamine (meth) acrylates, silicone (meth) acrylates and phosphazene (meth) acrylates or mixtures thereof;
-a second reinforcing layer adjacent to the first reinforcing layer or sandwiched between two sub-layers of the core layer;
-the one or more thermoplastic polymers of the first and second compositions are polyvinyl chloride;
-the one or more plasticizers in the first and second thermoplastic compositions are phthalate-free;
-the one or more plasticizers in the first and second thermoplastic compositions are selected from the group consisting of: lower alkyl esters of fatty acids, lower alkyl esters of aromatic diacids, benzoates, citrates, phosphates, sulfonates, alkyl esters of cyclohexane dicarboxylic acids, dialkyl esters of aliphatic dicarboxylic acids, alkyl esters of aromatic tricarboxylic acids, or alkyl esters of aromatic tetracarboxylic acids, except for alkyl esters of phthalic acid; and
-the wear layer further comprises a third thermoplastic composition, the second and third thermoplastic compositions having different colors and forming a shape on the upper surface of the component.
The invention also relates to a method of manufacturing a decorative surface covering as described above, comprising the steps of:
dispersing particles of said first thermoplastic composition on a conveying element to obtain a first layer of particles,
applying the at least one strengthening layer to the first particle layer,
dispersing particles of at least a second thermoplastic composition over the at least one reinforcing layer to obtain a second layer of particles,
-pressing and heating the first particle layer, the at least one strengthening layer and the second particle layer until melting or at least softening the first particle layer and the second particle layer to obtain an assembly after cooling, and
-using the assembly to produce a decorative surface covering.
In a specific embodiment, the step of pressing comprises pressing the first particle layer, the at least one strengthening layer and the second particle layer in a twin belt press.
The invention and its advantages will be better understood by reading the following description, given by way of example only, with reference to the accompanying drawings, in which:
figure 1 is a schematic partial cross-section of a surface covering according to the invention,
figure 2 is a schematic view of an apparatus for carrying out the method according to the invention,
figure 3 is a schematic view of the pressing system represented in figure 2, and
fig. 4 is a schematic diagram representing two variants of the pressing system represented in fig. 2 and 3.
Floor covering element
Referring to fig. 1, a decorative surface covering 1 according to the present invention is described. Other decorative surface coverings are similar to this one.
The decorative surface covering 1 is for example a tile or a roll.
As a variant (schematically shown in fig. 2), the decorative surface covering is a roll 3.
The surface to be decorated is for example a floor or a wall (not shown).
By "decorative" is meant that the surface covering 1 is intended to decorate a surface by changing its external appearance.
The decorative surface covering 1 has a thickness E along a thickness direction N defined by the decorative surface covering itself. The decorative surface covering 1 can have any shape that can lay a floor, as seen in the thickness direction N: rectangle, square, triangle, hexagon … …, etc.
The decorative surface covering 1 is intended to be applied to a surface adjacent to other decorative surface coverings (not shown) having the same or different shape or composition. Advantageously, the decorative surface covering 1 comprises locking tabs (which are known per se and not shown) enabling it to be connected to adjacent elements.
The decorative surface covering 1 comprises, in sequence in the thickness direction N, a component 5 and optionally a coating 10 on an upper surface 11 of the component 5. The coating 10 is preferably a radiation curable coating. Advantageously, the decorative surface covering 1 is free of any printed layer that would adhere directly (on the assembly) or indirectly (with an intermediate layer in between) on top of the assembly 5. In particular, no printed layer is laminated on or over the component 5.
The assembly 5 comprises, in the thickness direction N, a wear layer 5A, a first strengthening layer 5B, optionally a second strengthening layer 5C and a wear layer 5D.
As a variant a shown on the left side of fig. 4, the core layer 5 comprises only one reinforcing layer 5B.
As a further variant (not shown), there may be more strengthening layers than two strengthening layers 5B, 5C.
In the embodiment shown in fig. 1, the first reinforcing layer 5B and the second reinforcing layer 5C are adjacent to (overlap) each other. The first reinforcing layer 5B and the second reinforcing layer 5C are sandwiched between the core layer 5A and the wear layer 5D and at least partially penetrated (impregnated) by the core layer 5A and the wear layer 5D.
For example, each of the reinforcing layers 5B, 5C contains at least 50% glass fibers. Advantageously, they are made of glass fibers. For example, they are wool-like fabrics of glass fibers, that is to say nonwovens.
As variants, the reinforcing layers 5B, 5C may be woven glass fibers, glass grids (glass grids), spun yarns (yarns) or lenos.
In this embodiment, the strengthening layers 5B, 5C have the same composition, structure and thickness.
For example, the thickness of each of the strengthening layers 5B, 5C is comprised between 200 μm and 1000 μm.
As a variant (not shown), the reinforcing layers 5B, 5C may differ from each other in terms of composition, structure or thickness.
Such reinforcement layers are commercially available from Johns Manville (Johns Manville) under reference SH35/3 and holy gobian afos (Saint Gobain Adfors) under reference U35, for example.
Advantageously, the strengthening layers 5B, 5C are in contact with each other. This means that there is no thermoplastic material between them in the thickness direction N, except for the material resulting from the penetration of the adjacent reinforcement layers during the manufacturing process.
According to other variations, the two strengthening layers 5B and 5C may be spaced apart from each other in the thickness direction N. In this case, a thermoplastic material is present between the two reinforcement layers 5B and 5C.
In a particular variant B shown on the right side of fig. 4, the second reinforcing layer 5B is sandwiched within two sub-layers 64A,64B of the core layer 5A. This will be explained further below.
The core layer 5A comprises at least a first thermoplastic composition 12. In this example, the core layer 5A is made of a first thermoplastic composition 12.
Advantageously, the wear layer 5D is a homogeneous product defined by the 2019 standard ISO/FDIS 10581.
In the example shown in fig. 1, the wear layer 5D comprises a second thermoplastic composition 14 and a third thermoplastic composition 16, which are of different colors for a user (not shown) and form a shape 18 on the upper surface 11 of the component 5.
The second thermoplastic composition 14 advantageously comprises at least one first pigment.
Advantageously, the third thermoplastic composition 16 comprises at least one second pigment different from the first pigment.
In particular embodiments, the second thermoplastic composition 14 and the third thermoplastic composition 16 have different melt temperatures.
For example, as shown in FIG. 1, the second thermoplastic composition 14 forms a sheet 20.
Some of the flakes 20 form a portion of the upper surface 11, with the remainder of the upper surface being at least partially formed from the third thermoplastic composition 16.
As a variant (not shown), the second thermoplastic composition 14 forms a sheet and the third thermoplastic composition 16 forms a sheet.
Shape 18 is formed by the color contrast (color contrast) between second thermoplastic composition 14 and third thermoplastic composition 16.
As a variant (not shown), the wear layer 5D comprises only one thermoplastic composition.
As another variant (not shown), the wear layer 5D comprises more than two thermoplastic compositions having different colours.
The wear layer 5D is advantageously obtained by random fusion of particles of at least the second thermoplastic composition 14, which produces a decorative pattern, even in the absence of pigments.
The first thermoplastic composition 12 comprises one or more thermoplastic polymers, P1phr of one or more fillers, and P2phr of one or more plasticizers.
Here, "phr" is a unit, meaning "per 100 resins" indicating the mass content relative to the thermoplastic polymer. This means that the first thermoplastic composition 12 comprises P1 grams of the one or more fillers and P2 grams of the one or more plasticizers per 100 grams of the one or more thermoplastic polymers.
phr value is obtained as the ratio of mass values.
For example, the first thermoplastic composition 12 comprises between 25 and 45 weight percent of the one or more thermoplastic polymers, more preferably between 30 and 40 weight percent.
The second thermoplastic composition 14 comprises one or more thermoplastic polymers, P1'phr of one or more fillers, and P2' phr of one or more plasticizers.
P1 and P2 are greater than P1 'and P2', respectively.
The third thermoplastic composition 16 comprises one or more thermoplastic polymers, P1"phr of one or more fillers, and P2" phr of one or more plasticizers.
P1 and P2 are greater than P1 'and P2', respectively.
For example, the second thermoplastic composition 14 and the third thermoplastic composition 16 comprise between 30 wt.% and 60 wt.% of the one or more thermoplastic polymers, more preferably between 35 wt.% and 55 wt.%.
For example, P1 ranges from 100phr to 200phr and P2 ranges from 35phr to 60phr.
For example, P1 'and P1 "range from 40phr to 100phr, and P2' and P2" range from 10phr to 45phr.
Advantageously, the one or more thermoplastic polymers are PVC (polyvinylchloride).
Advantageously, the first thermoplastic composition 12, the second thermoplastic composition 14, and the third thermoplastic composition 16 do not contain any phthalate plasticizers.
The one or more phthalate-free plasticizers used are for example selected from the list consisting of: DINCH, DEHCH, DOTP (DEHT), DOA (DEHA), INB, DBT, DPT, dibenzoate DPGDB/DEGDB and mixtures thereof, ATBC, DOS, DBS, TXIB, FAME (fatty acid methyl ester), TEG-EH/3G8 (TEG-EH (triethylene glycol bis (2-ethylhexanoate))) and ESBO.
The phthalate-free plasticizer is selected from the group consisting of: lower alkyl esters of fatty acids, lower alkyl esters of aromatic diacids, benzoates, citrates, phosphates, sulfonates, alkyl esters of cyclohexane dicarboxylic acids, dialkyl esters of aliphatic dicarboxylic acids, alkyl esters of aromatic tricarboxylic acids, or alkyl esters of aromatic tetracarboxylic acids, except for alkyl esters of phthalic acid.
According to one embodiment, the coating 10 is a radiation curable coating and preferably comprises at least one radiation curable binder and at least one photoinitiator.
For example, the radiation curable coating agent comprises oligomers and/or polymers selected from the group consisting of: (meth) acrylic copolymers, polyether (meth) acrylates, polyester (meth) acrylates, epoxy (meth) acrylates, urethane (meth) acrylates, amino (meth) acrylates, melamine (meth) acrylates, silicone (meth) acrylates and phosphazene (meth) acrylates or mixtures thereof.
According to another embodiment, the radiation curable coating 10 comprises at least one additional ingredient selected from the group consisting of: reactive diluents, additives, light stabilizers, pigments, fillers, solvents, matting agents, and mixtures thereof for reducing viscosity.
Examples of compositions
Examples of the composition of the first thermoplastic composition 12 (core layer 5A) are provided in the following table:
thus, in the first thermoplastic composition 12, p1=150 phr and p2=43 phr.
The following is a compositional example of the second thermoplastic composition 14 (abrasion resistant layer 5D):
in the second thermoplastic composition 14, P1 '=76 phr, and P2' =28 phr.
In this embodiment, the third thermoplastic composition 16 is similar to the second thermoplastic composition 14 except that it does not contain the Yellow pigment Irgazin Yellow K2070 from BASF, but instead contains another pigment, such as a BLUE pigment, for example, EMBAPLAST BLUE P109.
In the third thermoplastic composition 16, P1 "=76 phr and P2" =28 phr.
Micro scratch resistance
In the embodiment of fig. 1, the decorative surface covering 1 has an upper surface 22 in the thickness direction N on the side defined by the wear layer 5D with respect to the core layer 5A formed by the coating 10, said upper surface 22 having a micro-scratch resistance of at least MSR-B2, preferably MSR-B1, according to standard EN 16094 of 3 months 2012.
The standard provides two standardized methods for testing micro-scratch resistance. Procedure B allows to divide the materials into five classes:
MSR-B1: no visible scratch was found after the test,
MSR-B2: there are only a few scratches that are made,
MSR-B3: a number of scratches are clearly visible and,
MSR-B4: a plurality of distinctly visible coarse and fine scratches, a partially visible Lissajous curve (Lissajous) pattern, and
MSR-B5: li Saru curve pattern is mixed with a large number of scratches with a pad friction-like area in between.
However, when uncoated, the upper surface 22 is formed by the upper surface 11 of the component 5, and said upper surface 11 has a micro-scratch resistance of at least MSR-B2, preferably MSR-B1, according to standard EN 16094 of 3 months 2012. Furthermore, it can be noted that only the wear-resistant layer 5D and the coating layer 10 have good micro-scratch resistance, whereas the core layer 5A does not. According to standard EN 16094, 3 in 2012, the bottom surface of the core layer 5A has a micro scratch resistance of MSR-B5.
Device for producing a decorative surface covering
With reference to fig. 2 and 3, an apparatus 30 for producing a decorative surface covering 1 (and many other decorative surface coverings) will be described.
The apparatus 30 comprises a pressing system 35 (also shown in fig. 3) providing the assembly 5, a coating line 40 for obtaining a board 45 or a web 3, and a finishing line 50 for obtaining a decorative surface covering, such as the decorative surface covering 1.
The pressing system 35 is, for example, a twin belt press. The pressing system 35 comprises a conveying element 52, the conveying element 52 being advantageously the first belt of a twin belt press and having an upper surface 54 adapted to carry the components of the assembly 5. The pressing system 35 includes a second belt 56, the second belt 56 having a lower surface 58 facing the upper surface 54. The pressing system 35 further includes: a unit 60 for dispersing particles 62 of the first thermoplastic composition 12 and obtaining a first layer of particles 64 on the transfer element 52; a unit 66 for superimposing the reinforcement layers 5B, 5C on the first particle layer; and a unit 68 for dispersing the particles 69 and other particles 70 of the second thermoplastic composition 14 and the third thermoplastic composition 16, respectively, and obtaining a second particle layer 72 on the transfer element 52.
The pressing system 35 is adapted to press perpendicular to the first particle layer 64 and the second particle layer 72.
The pressing system 35 is for example called
"twin belt press" refers, for example, to a press having at least two belts capable of transporting and pressing components of the assembly 5. In a variant (not shown), one or both of the transfer element 52 and the second belt 56 may be replaced by a number of belts having the same function as the belts replaced. In other words, the "twin belt press" is advantageously not limited to presses having exactly only two belts.
As a variant (not shown), the transfer element 52 is a belt different from the pressing belt of the twin-belt press.
As shown in fig. 3, the unit 66 comprises two systems 74, 76 known per se for respectively spreading out (unwind) the reinforcement layers 5B, 5C and guiding them towards the first particle layer 64.
As a variant (not shown), the unit 66 comprises only the system 74, or more than two systems 74, 76, for spreading the reinforcement layer as described above.
The system 76 is adapted to apply the strengthening layer 5C directly onto the strengthening layer 5B.
As a variant (not shown), the system 76 is adapted to apply the second strengthening layer 5C between the two sub-layers 64A and 64B of the first particle layer 64, as shown in the right side of fig. 4. In this case, the unit 60 is adapted to disperse the particles 62 under and over the second strengthening layer 5C.
Upper surface 54 and lower surface 58 are configured to run at the same speed to convey and compress first particle layer 64, reinforcement layers 5B, 5C, and second particle layer 72.
The pressing system 35 further comprises a system (not shown and well known per se) adapted to heat and cool the first and second particle layers 64, 72 and to adjust the thickness of the assembly 5.
The coating line 40 (fig. 2) is also known per se. The coating line 40 comprises a unit 78 for depositing a layer of a radiation curable coating agent 80 on the upper surface 11 of the component 5, and a unit 82 for curing the radiation curable coating agent and obtaining the coating 10. The coating line 40 further comprises a transport system 96 for transporting the component 5 with the additional coating 10.
The finishing line 50 is adapted to cut the plate 45 into pieces 95 having a predetermined shape, and optionally:
-beveling (level) the component, and/or
Providing a connection system on at least two opposite edges of the component, for example by milling (milling) operations, and/or
Applying an adhesive (not shown) on the component to obtain the decorative surface covering 1.
In another embodiment, the finishing line is adapted to produce the coil 3 by cutting and rolling the coated component 5.
Method for producing a decorative surface covering
The operation of the device 30 is derived from its structure and will now be described.
The pressing system 35 advantageously operates in a continuous manner. The unit 60 disperses the particles 62 so as to obtain a first particle layer 64 on the upper surface 54 of the transfer element 52.
The transfer element 52 transfers the first particle layer 64 under the system 74, which system 74 spreads the reinforcing layer 5B and applies it onto the first particle layer.
The transfer element 52 transfers the first particle layer 64 and the strengthening layer 5B under the system 76, and the system 76 spreads the second strengthening layer 5C and applies it directly onto the strengthening layer 5B.
The transfer element 52 transfers the first particle layer 64 and the strengthening layers 5B, 5C under the unit 68, the unit 68 dispersing the particles 69, 70 on the strengthening layer 5C to obtain the second particle layer 72.
The particles 69, 70 are dispersed in such a way that the second thermoplastic composition 14 and the third thermoplastic composition 16 form a shape 18 on the upper surface 11 of the second particle layer 72.
The stack of superimposed layers is then pressed between the conveying element 52 and the second belt 56. The set is also heated to at least partially melt the first particle layer 64 and the second particle layer 72. As a result, the strengthening layers 5B, 5C are at least partially penetrated by the molten particle layer while remaining in contact with each other. This also forms the core layer 5A and the wear layer 5D of the assembly 5, as shown in fig. 1. After cooling, the assembly 5 appears as a solid.
The pressing system 35 also sets the desired thickness of the component 5 obtained at the outlet of the press.
The assembly 5 is then used to produce a decorative surface covering 1. This step does not involve any adhesion of the printed film on or over the assembly 5 and in particular does not involve any lamination substep.
The assembly 5 enters the coating line 40 (fig. 2).
The unit 78 provides a layer of radiation curable coating agent 80 applied to the assembly 5. Unit 82 cures the layer of radiation curable coating agent 80 and forms coating 10.
The plate 45 is obtained by cutting the product continuously leaving the coating line 40. The plate 45 has the structure of a decorative surface covering 1.
The boards 45 then enter the finishing line 50 where they are cut to the desired dimensions and chamfered to obtain a decorative surface covering. Advantageously, at least two opposite edges of the tile are milled to form a connection system (not shown). Optionally, an adhesive (not shown) is applied on the back of the tile for tile installation.
Alternatively, the finishing line 50 produces a web 3 that may or may not be cut.
Due to the above features, no further lamination step is required to obtain a decorative surface covering that is decorative and resistant to delamination. The process provides a decorative surface covering that is both durable and aesthetically pleasing at a relatively low cost.

Claims (15)

1. Decorative surface covering (1) defining a thickness direction (N) and comprising an assembly (5), said assembly (5) having, along said thickness direction (N):
a core layer (5A) comprising a first thermoplastic composition (12), said first thermoplastic composition (12) comprising one or more thermoplastic polymers, P1phr of one or more fillers and P2phr of one or more plasticizers,
-at least one strengthening layer (5B), and
an abrasion resistant layer (5D) comprising at least a second thermoplastic composition (14), said second thermoplastic composition (14) comprising one or more thermoplastic polymers, P1'phr of one or more fillers and P2' phr of one or more plasticizers,
wherein P1 and P2 are greater than P1 'and P2', respectively.
2. The decorative surface covering (1) according to claim 1, wherein the at least one strengthening layer (5B) comprises at least 50% glass fibers.
3. The decorative surface covering (1) according to claim 1 or 2, which is devoid of any printed film on or over the component (5).
4. A decorative surface covering (1) according to any one of claims 1 to 3, further comprising a coating layer on the wear layer (5D), the coating layer (10) comprising a radiation curable coating agent (80).
5. The decorative surface covering (1) according to claim 4, wherein the radiation curable coating agent comprises an oligomer and/or polymer selected from the group consisting of: (meth) acrylic copolymers, polyether (meth) acrylates, polyester (meth) acrylates, epoxy (meth) acrylates, urethane (meth) acrylates, amino (meth) acrylates, melamine (meth) acrylates, silicone (meth) acrylates and phosphazene (meth) acrylates or mixtures thereof.
6. The decorative surface covering (1) according to any one of claims 1 to 5, comprising a second reinforcing layer (5C), the second reinforcing layer (5C) being adjacent to the first reinforcing layer (5B) or sandwiched between two sub-layers (64 a, 64B) of the core layer (5A).
7. The decorative surface covering (1) according to any one of claims 1 to 6, wherein the one or more thermoplastic polymers of the first composition (12) and the second composition (14) are polyvinyl chloride.
8. The decorative surface covering (1) according to any one of claims 1 to 7, wherein the one or more plasticizers in the first and second thermoplastic compositions (12, 14) are phthalate-free.
9. The decorative surface covering (1) according to claim 8, wherein the one or more plasticizers in the first thermoplastic composition (12) and the second thermoplastic composition (12, 14) are selected from the group consisting of: lower alkyl esters of fatty acids, lower alkyl esters of aromatic diacids, benzoates, citrates, phosphates, sulfonates, alkyl esters of cyclohexane dicarboxylic acids, dialkyl esters of aliphatic dicarboxylic acids, alkyl esters of aromatic tricarboxylic acids, or alkyl esters of aromatic tetracarboxylic acids, except for alkyl esters of phthalic acid.
10. The decorative surface covering (1) according to claims 1 to 12, wherein the wear layer (5D) further comprises a third thermoplastic composition (16), the second thermoplastic composition (14) and the third thermoplastic composition (16) having different colors and forming a shape (18) on the upper surface (11) of the component (5).
11. The decorative surface covering (1) according to any one of claims 1 to 10, wherein the second thermoplastic composition (14) comprises between 30 and 60 wt% of the one or more thermoplastic polymers.
12. The decorative surface covering (1) according to claim 11, wherein the second thermoplastic composition (14) comprises between 35 and 55 wt% of the one or more thermoplastic polymers.
13. The decorative surface covering (1) according to any one of claims 1 to 12, wherein P1 'ranges from 40phr to 100phr and P2' ranges from 10phr to 45phr.
14. Method of manufacturing a decorative surface covering (1) according to any one of claims 1 to 13, the method comprising the steps of:
dispersing particles (62) of said first thermoplastic composition (12) on a conveying element (52) to obtain a first layer of particles (64),
-applying said at least one strengthening layer (5B) on said first granular layer (64),
dispersing particles (69) of at least said second thermoplastic composition (14) over said at least one reinforcing layer (5B) to obtain a second layer of particles (72),
-pressing and heating the first particle layer (64), the at least one strengthening layer (5B) and the second particle layer (72) until melting or at least softening the first particle layer (64) and the second particle layer (72) to obtain the assembly (5) after cooling, and
-producing the decorative surface covering (1) using the assembly (5).
15. The method of claim 14, wherein the step of pressing includes pressing the first particle layer (64), the at least one strengthening layer (5B), and the second particle layer (72) in a twin belt press.
CN202280038230.XA 2021-04-19 2022-04-15 Wear-resistant decorative surface coverings and process for making same Pending CN117412855A (en)

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LU102788A LU102788B1 (en) 2021-04-19 2021-04-19 Wear resistant decorative surface coverings, and process for manufacturing thereof
LULU102788 2021-04-19
PCT/EP2022/060170 WO2022223486A1 (en) 2021-04-19 2022-04-15 Wear resistant decorative surface coverings, and process for manufacturing thereof

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SE513280C2 (en) * 1998-11-05 2000-08-14 Forbo Int Sa Floor coatings and process for its preparation
EP3330055A1 (en) * 2016-12-01 2018-06-06 Tarkett GDL S.A. Floor tile and process for manufacturing thereof
FR3073539B1 (en) * 2017-11-13 2020-05-15 Gerflor RIGID PANEL FOR THE PRODUCTION OF A FLOOR COVERING
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